ABB SACE Emax 2 E2.2 Installation instructions

—
INSTRUCTION HANDBOOK
1SDH002304A1001 - ECN000285442
EMAX 2 E2.2
Disassembly instructions

3
Disassembly instruction emaX 2 e2.2
1. SCOPE
Scope of this document is to illustrate the step-by-step disassembly process of ABB SACE Emax 2 E2.2
air case circuit breaker equipped with an electronic trip unit (type Ekip TOUCH).
Document is focused on Emax 2 E2.2 3p IEC version, anyway it allows to cover other versions of Emax
2 E2.2 circuit breaker equipped with an electronic trip unit with just few slight differences to be taken
into account.
Gloves Glasses Safety shoes Protective clothes
4. TOOLS
Disassembly operations require the use of tools (e.g. screwdriver, torx key, pliers, …); tools to be used
are specified inside each phase of the disassembly process (see Chapter 6).
3. PERSONAL PROTECTIVE EQUIMENT (PPE)
When performing disassembly, following safety Personal Protective Equipment (PPE) must be worn:
2. SAFETY NOTES
Before proceeding with any disassembly operation, it’s mandatory to put the circuit breaker in open
position and make sure that the springs of the operating mechanism are discharged.
For handling and lifting circuit breakers refer to section “Unpacking and handling” of Emax 2 “Installa-
tion, operation and maintenance instructions for the installer and the user” document. Improper lifting
can result in death, serious injury to persons and damage to the equipment; never lift a circuit breaker
above other people. The trained personnel in charge of handling and lifting must use appropriate safe-
ty equipment.
Disassembly operations of circuit breakers must be performed by qualified and skilled personnel in
the electrical field (IEV 195-04-01: person with relevant education and experience to enable him or her
to perceive risks and to avoid hazards which electricity can create) and having a detailed knowledge of
circuit breakers.
Disassembly activites must be performed in an ergonomic workspace able to ensure protection of per-
sons demanded to perform disassembly activities.
Applicable national legislation and international standards in force at the time of disassembly of circuit
breakers must be taken into account in addition to prescriptions illustrated in this document.
ABB declines any responsibility for injury to people or damage to property resulting from a failure to
comply with the instructions set out in this document and with any applicable safety standard.

4
INSTRUCTION HANDBOOK
Description Position inside circuit breaker Quantity
Base In sliding contacts block 
Cover In sliding contacts block 
Auxiliary position contacts cap In sliding contacts block 
Right side wall In sliding contacts block 
Flat cables assembly In sliding contacts block 
Connector cables assembly In sliding contacts block 
Sliding contacts base In sliding contacts block 
Ekip measuring blind module printed circuit board Mounted on the trip unit 
Plug Mounted on the trip unit 
Rating plug printed circuit board Mounted on the trip unit 
Rating plug case Mounted on the trip unit 
 Mounted on the trip unit 
Battery cover Mounted in the trip unit 
Battery Mounted in the trip unit 
Display printed circuit board Mounted in the trip unit 
Display Mounted on the trip unit 
Back plane Mounted on the trip unit 
Trip unit case Mounted on the trip unit 
Trip unit back cover Mounted on the trip unit 
Trip unit printed circuit board Mounted in the trip unit 
 Mounted on the terminal box 
 Mounted in the terminal box 
Connectors Mounted on the terminal box 
 Mounted on the terminal box 
 Mounted on the terminal box 
Terminal box case Mounted on the terminal box 
Left MID On the left part of the circuit breaker 
CD block cover Mounted in the CD 
Front of the CD Mounted on the CD 
Position indicator Mounted in the CD 
Feeler Mounted in the CD 
CD block lever Mounted on the CD 
Releases door Mounted on the MID 
MID pawl Mounted on the MID 
Spacers Mounted in the MID 
MID reset lever Mounted in the MID 
Mechanical reset anchor Mounted in the MID 
Trip coil support base Mounted in the MID 
Trip coil cover Mounted in the MID 
Trip coil Mounted in the MID 
Flat cover Mounted on the MID 
5. SEPARATE TREATMENT
Table below lists parts requiring a separate treatment adding information about part location inside
circuit breakers and related quantity.

5
Disassembly instruction emaX 2 e2.2
If disassembled parts require a separate treatment a specific indication is provided inside each phase
with reason why for the separate treatment (see Chapter 6).
6. DISASSEMBLY PROCESS
Circuit breakers disassembly process is constituted by a sequence of operations to be performed on
products after their dismounting from original installation. For each phase following information are
provided:
 
 
 
 
 
applicable)
 
Description Position inside circuit breaker Quantity
Auxiliary flat assembly Mounted on the MID 
RTC micro lever Mounted in the MID 
MID main structure Mounted in the MID 
Springs charging lever Mounted on the operating mechanism 
Operating mechanism Mounted on the center of the circuit breaker 
Auxiliary contacts cam Mounted on operating shaft assembly 
Cam Mounted on operating shaft assembly 
Lever Mounted on operating shaft assembly 
Measuring module connector Mounted behind the trip unit and connected with poles 
Protections Mounted in correspondence of rear terminals 
Spacers Mounted in correspondence of rear terminals (for UL only) 
Arc quenchings Mounted in arcing chambers 
Spacers Mounted in arcing chambers 
Sensors plugs Mounted in poles 
Sensors Mounted in poles 
Cables Mounted in poles 
Insulating protections Mounted in poles 
Insulation protections Mounted in poles 
Contacts spacers Mounted in poles 
 
current rating up to 1600A

6
INSTRUCTION HANDBOOK
Tools
Torx key
Flat screwdriver
6.1 PHASE 1 – CIRCUIT BREAKER FRONT COVER AND OPERATING
MECHANISM COVER
1
By means of the flat screwdriver turn of 90°
the 2 screws fixing the trip unit transparent
protection to the circuit breaker.
4
By means of the cross screwdriver unscrew the
4 screws fixing the front cover to the circuit
breaker main structure.
6
By means of the torx key unscrew the 2 screws
fixing the 2 plugs to the front cover.
3
Manually remove the racking in and out lever
located in the bottom part of the circuit
breaker.
5
Manually remove the front cover.
2
Manually remove the trip unit transparent
cover.
Actions to be performed
Cross screwdriver
No. 8

7
Disassembly instruction emaX 2 e2.2
7
Manually remove the 2 plugs.
11
By means of the flat screwdriver push the pin
as indicated by the arrow and after let the
the spring and the T.U. Reset signalling plug
automatically separate from the T.U. Reset
metal support.
9
Manually remove the T.U Reset assembly.
8
By means of thr torx key unscrew the 2 screws
fixing the T.U. Reset assembly to the front
cover.
12
By means of the torx key remove the 2 screws
fixing the plug to the circuit breaker front
cover.
10
By means of the flat screwdriver remove the 2
benzings mounted on the T.U. Reset assembly.

8
INSTRUCTION HANDBOOK
13
Manually remove the plug.
15
By means of the cross screwdriver unscrew
the screw located on the side of operating
mechanism cover.
14
Manually push down the springs charging lever
and by means of the cross screwdriver unscrew
the 2 screws located behind the springs
charging lever fixing the operating mechanism
cover to the circuit breaker main structure
and always by means of the cross screwdriver
unscrew the screw located in the bottom right
part of the operating mechanism cover fixing
it to the circuit breaker main structure.
16
Manually complete the removal of the
operating mechanism cover.

9
Disassembly instruction emaX 2 e2.2
Disassembled parts
 
Metal)
 
 
 
 
 
 
 
 
 
 

10
INSTRUCTION HANDBOOK
6.2 PHASE 2 – SLIDING CONTACTS BLOCK
Actions to be performed
Tools
Torx key
No. 8
No. 30
Pliers
Flat screwdriver (x2)
Cutter
17
By means of the torx key (size 30) unscrew the

both sides of the sliding contacts block to the
circuit breaker main structure.
20
Manually remove the base and the cover.
19
Move the sliding contacts block as shown in
the picture and by means of the torx key (size
8) unscrew the 6 screws fixing the base and
the cover.
18
Manually remove the 2 side walls located on
the sides of the sliding contact block.